VERDER JEC JRZP Series Installation and operation manual

Operating & Maintenance Manual
J
JE EC C J JR RZ ZP P S Se er ri ie es s
Circumferential Piston Pumps

1
CONTENTS
GENERAL
General Information ….…………………………………………………………………………….………..………….
Intended Use .………………………………………………………………………………….....………………………
Construction ………………………………………………………………………………….....…………………………
Packaging & Transport ….……………………….…………………………………………………..……………......
Storage …….……………………………………….………………………………………….....…………………………
SAFETY
DO’S and DON’TS ………………………………………………………………………………………………………….
Warranty ……………………………………………………………………………….………………………………......
INSTALLATION
Installation …………………………………………………………………………………………………………………..
Start Up ……………………………………………………………………………………………………………………….
MAINTENANCE
Rotor Case Disassembly ……………………………………………………….……..…………………………………
Inspection ………………………………………………………………………….……..…………………………………
Seal Maintenance ……………………………………………………….……..…………………………………………
Rotor Case Assembly ………….……………………………………………………..…………………………………
Gearbox Maintenance ……………………………………………………………………………………………….…
OPERATION
Troubleshooting …………………………………………………………………………………………………………..
Cleaning ………………………………………………………………………………………………………………………
TECHNICAL INFORMATION
Technical Data ……………………………………………………………………………………………………………..
Dimensional Drawing …………………………………………………………………………………………………….
PARTS LIST
Exploded View & Parts List / ZP015 …………………………………………………………………………………
Exploded View & Parts List / ZP030, ZP060, ZP130 ……………………………………………………………
* APPENDIX
Lubrication …………………………………………….…………………….…………………………………………….
Certificates
3-A (3-A Sanitary Standards, Inc.) ………………………………….……………………………………………
EHEDG (European Hygienic Engineering & Design group) …………………………………………………
DOCs
ATEX (European Explosion Proof Certificate) ………………………………………………………………….
CE (Declaration Of Conformity) ……………………………………………………………………………………
1935/2004 (EC) …………………………………………………………………………………………………………
FDA ….………………………………………………………………………………………………………………………
2
2
3
4
4
5
6
7
7
8
10
11
15
20
24
25
26
27
28
34
51
52
53
54
55
56
57

2
GENERAL
GENERAL INFORMATION
Thank you for your purchasing JEC products!
This manual is a part of the JRZP series Circumferential Piston Pumps describes safe and appropriate
operation during operating and in all life cycles.
This contains instructions for installation, operation, disassembly and assembly, maintenance
procedures, troubleshooting and a complete parts list for all.
Read and completely understand this manual to learn how to service these pumps prior to operating
or servicing product and observe to pay special attention to the warnings.
This must always be available at the installation location since no liability will be assumed for any
damage or operational malfunctions arising from non-compliance with these operating instructions.
INTENDED USE
The pump is only to be used for the media pumping agreed in the applicable data sheet or
specification. Any other application beyond the intended use or conversion of the pump without
written agreement with the manufacturer shall be deemed to be not in accordance with the intended
use.
The pump may only be started up for the first time if it has been ensured that all safety devices are
completely fitted and functional.
If any areas are subject to have the risk of explosion, the relevant explosion-proof designed pumps to
be used.
Intended use also covers compliance with the conditions of operation, servicing and maintenance
specified by the manufacturer.
The pump is only to be put into operation filled with medium to be pumped.
Before starting up ensure that;
- Open the valves on the suction side completely to avoid cavitation and,
- Open the valves on the discharge side open completely to avoid exceeding the permitted
differential pressure of the pump
-Discharge-side safety measures should be done (e.g. safety valve) to protect the pump from
non-permitted excess pressure
-Protection against contact for hot, cold and moving parts must not be removed during operation

3
CONSTRUCTION
JRZP series Circumferential Piston Pumps can be ordered with bare shaft, i.e. pumps without motor
or common bed.
Or, ordered as a complete unit with drive motor, coupling & guard, common bed (or trolley) and
layout described as below.
Example Layout of pumps with complete unit
①Common bed, ②Drive unit, ③Coupling & coupling guard, ④Gearbox,
⑤Rotor case with inlet & outlet ports, ⑥Front cover
The nameplate is fixed on the gearbox shown an example as below.

4
PACKAGING & TRANSPORT
JRZP series are shipped in non-returnable wooden packaging.
Unpack the pump/unit upon delivery and inspect it for visible transport damage.
Any damage occurred during the transporting has to be immediately reported to the transport agent
after receipt of the consignment. Do not put the damaged products into operation.
The pumps need to be transported and secured with care to ensure no damage caused. Lifting
equipment (hoist) and load securing straps must be placed with sufficient load capacity.
Make sure you sent the pump down on a sufficient table, horizontal surface.
Below picture of complete unit with drive & common bed is shown for the example.
STORAGE
If the pumps need to be stored temporarily, it should be sufficiently preserved under normal
environmental conditions and must not be exposed to the weather for any significant period of time.
Heed below measures when required to be stored longer period.
1. Protect pumps with dust, dirt, water or any other harmful environmental factors. Coat all
non-painted surfaces with acid-free and resin-free grease.
2. Do not grease stainless steel parts and non-metallic parts.
3. Cover all openings of pressure and suction ports.
4. Drain water when using it as flushing/quench medium for shaft seal.

5
SAFETY
DO’S & DON’TS
DO read and understand these instructions before installing or using the pump.
DO use JEC spare parts when replacing a component of the pump.
DO NOT service the pump while it is running.
DO NOT place the pump in an application where the service ratings are exceeded.
DO NOT modify the pump. Modifying the pump creates unsafe conditions and voids all
warranties.
SAFETY PRECAUTIONS WHEN INSTALLING PUMP
DO use an authorized electrician when connecting the pump.
DO observe the mechanical limits of the pump (refer to the pump performance sheet).
DO install a throttling valve in the discharge line.
DO earth the base plate of pump to avoid the potential build up of static electricity.
DO NOT install a throttling valve in the suction line.
SAFETY PRECAUTIONS WHEN OPERATING PUMP
DO only qualified personnel should operate this pump.
DO NOT start the pump until all personnel are clear.
DO NOT touch the pump or the lines when pumping hot fluids or when performing Clean In Place
(CIP) procedures.
DO NOT run the pump with BOTH the suction inlet and discharge outlet blocked. Running the
pump with the inlet the blocked will cause serious damage to the pump.
DO NOT check pump rotation with liquid in the pump.
DO NOT run the pump with the front cover removed. The screws and screw case could be
damaged or may cause severe injury.
DO NOT operate the pump with removed the safety guard or shroud.
SAFATY PRECAUTIONS WHEN SERVICING PUMP
DO ensure the pump is cool to touch before performing service.
DO relieve all pressure and drain all fluids from pump and connected piping before performing
service.
DO ENSURE POWER TO THE UNIT HAS BEEN UNPLUGGED PRIOR TO PERFORMING
ANY PUMP MAINTENANCE OR CLEANING.
DO exercise caution and wear protective clothing when using lye or acid for cleaning.

6
WARRANTY
TERMS & CONDITIONS
All terms & conditions and prices of sale are based on the applicable JEC price list at the time an
order from Customer is received by JEC and are subject to change without notice. No assignment
of the purchaser’s rights may be made without consent of JEC.
JEC warrants its Product from defects in materials and workmanship for a period of one (1) year
from the shipment date, providing it has been used as recommended and in accordance with
recognized piping practice, and providing it has not been worn out due to severe service, normal
tea and wear or subjected to accident, misuse or improper maintenance. This warranty extends
only to the original Buyer.
This warranty is expressly in lieu of any other warranties expressed or implied, including but not
limited to any implied warranty of merchantability or fitness for a particular purpose.
All claims must be in writing and must be mailed or delivered by purchaser within thirty (30) days
after purchaser learns of the facts upon which such claim is based. Any claim not made in writing
and within the time period specified above shall be deemed waived.
Purchaser’s sole and exclusive remedy and JEC Ltd.’s maximum liability for claims arising
hereunder or for negligence for any and all losses and damages resulting from any cause shall be
either the repair or replacement of defective components or pumps verified by JEC.
In no event, including in the case of a claim for negligence, shall JEC Ltd. be liable for incidental
or consequential damages including loss of profits.
No person, including any representative, employee or agent of JEC, is authorized to assume on
behalf of JEC, any liability or responsibility in addition to or different from that described in this
provision. Any and all representations, promises, warranties or statements that are in addition to
or different from the terms of this provision are of no force or effects.
RECEIVING INSPECTION
Ports are rubber capped at the factory to keep out foreign objects. If covers are missing or
damaged, a thorough inspection of fluid head, by removing pump cover, is recommended. Be
sure pumping head is clean and free of foreign material before rotating shaft.
LOSS OR DAMAGE
If your pump has been lost or damaged in transit, immediately file a claim at once with the
delivering carrier and ask for inspector to call. The carrier has signed the Bill of Lading
acknowledging that the shipment has been received from us in good condition.
We shall assist you in every way in collecting claims for loss, or damage, however, we are not
responsible for the collection of claims or replacement of material.

7
INSTALLATION
INSTALLATION
1. Mounting surface should be flat and level.
2. The suction line should be kept as short as possible and present minimum friction loss.
3. Suction and discharge lines must be fully supported and installed so that no expansion or
shock forces act on the pump which could lead to a bad influence.
4. Ensure sufficient clearance around the motor and pump.
5. Before connecting pipelines, check the location of suction and discharge.
6. Ensure the pipelines are connecting correctly and tightly.
7. The suction line should be kept as short as possible and present minimum friction loss.
8. Suction and discharge lines must be fully supported and installed so that no expansion or
shock forces act on the pump which could lead to distortion.
9. Ensure sufficient clearance around the motor and pump.
START UP
1. Before connecting the suction and discharge pipe work the entire system must be thoroughly
cleaned to prevent damage from welding, grinding and other residues.
2. Before starting, bump the motor to check if the motor fan is rotating clockwise or
counterclockwise when seen from the motor back. If the motor fan cannot be seen, look
through the pump case adaptor after takeoff motor shroud. (Bump means to momentarily
apply power to the motor and then immediately remove power).
3. Direction of rotating must only be checked with a completely filed system. Where double
mechanical shaft seals are installed the flush supply must be operational. Any dry running will
result in seal damage.
4. The motor rating plate should be checked to ensure that it is in accordance with the available
electrical supply. It is essential that the full load current is not exceeded to prevent motor
overload.
5. Before start up any safety guards required by local statutory regulations should be fitted.
Pay attention to circumstances that could indicate pump cavitation;
1. Low pressure in the suction line due to bad suction conditions.
2. Air in the suction-line.
3. Pumping temperature is too high.
4. Pump is oversized.

8
MAINTENANCE
ROTOR CASE DISASSEMBLY
Prior to removal of pump, the shut-off valves in the suction and discharge pipe work must be closed.
If there is any risk that product may be hardened, crystallized or frozen in the pump, it should be
thoroughly drained and cleaned immediately after use. Similar attention must be applied to the seal
flushing system. Remove power before servicing to prevent from any unintended start of the pump
by authorized electrician.
Remove Front cover and O-ring after removing the four cap
nuts from the front cover. If it is stuck, tap on the front cover
with a soft mallet and pull out.
If the front cover was stuck at dowels, insert flat driver at the
two groove of between front cover and rotor case to be
separated.
Place the plastic round bar between the rotors and remove
rotor bolts with the rotor bolt extraction tool. To avoid damage
rotor bolt, the extraction tool should be position in the groove
properly and pushed by left hand strongly.
Turn the first rotor bolt as counter-clockwise and remove both
of rotor bolts.
The rotors can be removed from the pump case by pulling
straight.
If it is stuck tight, alternately tap on the back of the inlet and
outlet ports with soft mallet after removing the four hex nuts of
stud bolts securing the case to the gearbox.
Treat carefully the rotors to avoid damage.
Remove rotating seal rings from the backside of the rotors as
shown in Figure 4. Then, O-ring for rotors can be removed.
Fig. 1
Fig.2
Figure 1
Fig. 3
Fig. 4

9
Clean and examine all of the pump components for damage. Replace damaged
components as required. JEC recommends replacing all the wetted elastomers during
reassembly.
If you want to replace the seal ring only, you can remove the old one & insert the new
one easily just after removing rotors without dismantling rotor case.
Refer to ‘Page 12’for the further procedure.
In case of removing seal body, it can be easily dismantled from
rotor case after removing stationary seal ring and O-ring of the
rotor case.
Remove four hex nuts of the stud bolts securing the rotor case to
the gearbox.
After pulling out both rotors and four hex nuts, rotor case can be
separated by sliding along the stud bolt and pulling out from the
gearbox. Inspect the rotor case for wear, clean and continue to
seal maintenance (Refer to ‘Page 11’), if needed.
If it is stuck tight, tap alternately on the back of the inlet and outlet
ports using soft mallet as shown in Figure 7.
After rotor case removed, handle and place carefully the top &
bottom shim(s) which shafts are associated to keep the right track
of position to avoid lost, damaged or misalignment.
They are installed accordingly at the factory for that particular
body.
Fig. 5
Fig. 6
Fig. 8
Fig. 7

10
INSPECTION
While performing standard maintenance or cleaning, check for signs of damage or extreme wear.
A simple inspection may show signs of a problem long before it becomes serious. Detection of such
problems can avoid costly repairs and reduce down time.
1. Inspect O-rings and seals for re-use. Worn O-rings and seals should be replaced.
2. Inspect seal faces for chipping, scratches or cracks. Replace any seal faces if damaged.
3. Inspect shaft shoulder matched to rotors and other metal parts worn or damaged.
4. Inspect rotor galling sign among the rotor case, front cover and rotors. It must be removed
or replaced.
5. Inspect bur of the rotor bolt groove. It must be removed or replaced.

11
SEAL MAINTENANCE
JRZP series is designed by ‘Front Loading Seal’ that the mechanical seal system can be changed or
replaced without removing rotor case.
Check & inspect all components of seal replacement kit carefully whether there is any damage or
defect before installing. If any chipping, crack or scratch found during inspection, do not reuse them
and replace the damaged one.
Below shows the Single mechanical seal (Figure 9), Double mechanical seal (Figure 10) and PTFE
Triple lip seal with ceramic coated sleeve (Figure 11).
The seal ring can be easily removed from rotor by hand. This is
common for the Single mechanical and Double mechanical seal.
Put rotor face down on the table and pull out the seal ring and
O-ring from rotor.
Pre-assemble NEW O-ring and seal ring then insert into the rotor.
When inserting seal ring, the pin of rotor has to be into the hole of
seal ring.
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

12
Single Mechanical Seal Maintenance
Remove the Seal ring from the rotor case & rotor and inspect
them. If any seal is damaged, do not re-use and replace it.
Clean both shaft ends and the rotor case before assembling. Push
the replacing NEW Seal ring into the rotor case O-ring and turn fit
into the seal pins on the seal body after Rotor Case Assembly
(Refer to ‘Page 15’).
In order to disassemble current seal body, pull out the current
O-ring and seal body sequentially.
Upside down the rotor case, then remove ‘SEAL BODY STOP RING’
for seal body.
But, we don’t remove it normally.
Replace NEW ‘SEAL BODY STOP RING’ for seal body into the rotor
case.
Insert NEW ‘SEAL BODY STOP RING’ by hammering as shown
Figure 17.
Insert the replacing NEW seal body and O-ring into the rotor case
sequentially.
See ‘Rotor Case Assembly’ on ‘Page 15’to continue.
Fig. 14
Fig. 18
Fig. 17
Fig. 16
Fig. 15

13
Double Mechanical Seal Maintenance
Remove the Seal ring from the rotor case & rotor (shown in Figure
19) and inspect them. If any seal is damaged, do not re-use and
replace it.
Clean both shaft ends and the rotor case before assembling. Push
the replacing NEW Seal ring into the rotor case O-ring and turn fit
into the seal pins on the seal body after Rotor Case Assembly on
page 15.
In order to replace the product side of mechanical seal, refer to Figure 16~18.
While, in order to replace the flushing side of mechanical seal, refer to Figure 20~22.
After rotor case removed (‘Page 9 & 10’), pull out and remove the
Double seal rotating part from the shaft and inspect them.
If any Double seal rotating part, Seal face and O-ring is damaged,
do not re-use and replace it.
Clean both shaft ends and the rotor case before assembling.
Lubricate the replacing NEW Double seal rotating part O-ring and
install it in the Double seal rotating part. Slide and insert the
Double seal rotating part on the shaft making sure to line the slot
on the Double seal rotating part to the pin in the shaft.
Place the rotor case face down on the table and pull out carefully
the Double seal ring (53) out of rotor case by hands shown in
Figure 21. Carefully treat Double seal ring (53) because carbon is
fragile material.
Lubricate the replacing double seal ring or O-ring and insert it
into the rotor case and fit into the Seal pin properly.
After remove Double seal ring (53), check whether wave spring
(61) has been damaged or not. If wave springs (61) were
damaged, replace it as shown Figure 22.
See ‘Rotor Case Assembly’ on ‘Page 15’to continue.
Fig. 22
Fig. 19
Fig. 20
Fig. 21

14
Triple Lip Seal Maintenance
After removing rotor case (‘Page 9 & 10’), pull out and remove
Ceramic coated sleeves from the shaft and inspect them. If any of
them is damaged, do not re-use and replace it.
Clean both shaft ends and the rotor case before assembling. Slide
& insert the sleeves onto the shafts until it seats on the shaft
shoulder. Align the slot in the shaft sleeve to the drive pin on the
shaft.
Place the rotor case face down on the table and loosening the
wrench bolts and washers using appropriate wrench as shown in
Figure 24.
Pull the Lip seal out of the rotor case.
And insert the replacing NEW Lip seal, making sure the holes in
the seal to be lined up with the pins in the rotor case. Recap and
tighten the Lip seal gland with wrench bolts.
See ‘Rotor Case Assembly’ on ‘Page 15’to continue.
When assembling Lip seal, the pin of rotor case has to be into the
hole of Lip seal. Before assembling it to rotor case, the food grade
grease should be applied between each lips.
During the assembly the rotor case to the gearbox, Lip seal caused the tight insert to the sleeve. In
this case, tap rotor case using soft mallet or fasten the Stud nut can make it easier to insert for
assembly between the rotor case and the gearbox.
Fig. 23
Fig. 25
Fig. 24

15
ROTOR CASE ASSEMBLY
Before installing the rotor case (31) to the gearbox (1A), make sure to clean the surface of rotor case
& gearbox and check the shim plates surely between rotor case and gearbox as originally.
Assemble the rotor case (31) onto the gearbox (1A) and secure
the four hexa-nuts (46) with reference of below torque value.
Series
ZP015
ZP030
ZP060
ZP130
Nut size
M8
M10
M14
M14
Torque (N·m)
30
34
80
80
Insert stationary seal body inside hub in pump case as Figure 27,
and make sure of that pins on the seal body should be engaged
firmly inside seal pins on seal Seal Body Stop Ring.
Insert new case O-ring inside groove with lube.
Assemble seal ring inside hub of pump case.
Put rotor O-ring in advance and the rotating seal rings on the back
of rotors.
Be sure that notch of seal ring should be engaged into seal pin
firmly.
Fig. 26
Fig. 27
Fig. 29
Fig. 28

16
Insert rotors along the shaft carefully without seal ring separated
from rotor as Figure 30.
Tighten rotor bolts with the rotor bolt extraction tool firmly.
Be sure not to make any bur on the rotor bolt groove during this
process. It may cause the serious problem such as galling on the
rotor case and if it happened, it must be removed.
Series
ZP015
ZP030
ZP060
ZP130
Bolt size
M10
M14
M18
M18
Torque (N·m)
20
40
100
100
Install the NEW O-ring inside of the front cover (32) and slide the
front cover over the stud. Thread cap nuts (33) on the studs and
tighten using an appropriate wrench in an opposing manner
shown in Figure 33.
Series
ZP015
ZP030
ZP060
ZP130
Nut size
M8
M10
M14
M14
Torque (N·m)
14
17
30
30
Use feeler gauges and depth micrometer to verify the back and radial clearances
between the rotors and the rotor case. A depth micrometer should be used to verify the
front clearance.
Fig. 32
Fig. 30
Fig. 31

17
Rotor Clearance
Rotor clearance must be precisely maintained to provide maximum pumping efficiency, yet prevent
contact between rotors, rotor case, and front cover during operation.
If pumping efficiency is lower than expected or if parts contact has occurred during operation (Within
rated differential pressure), check the rotor clearances and adjust, if incorrect.
Standard Rotor Clearances (mm)
Material
Clearance \ Model No.
ZP015
ZP030
ZP060
ZP130
Illium8
Back Face
0.05
0.05
0.10
0.10
Rotor to Body
0.05
0.05
0.13
0.13
Front Face
0.13
0.13
0.20
0.20
SUS316L
Back Face
0.15
0.15
0.25
0.25
Rotor to Body
0.15
0.15
0.28
0.28
Front Face
0.23
0.23
0.35
0.35
There are two areas of rotor clearances as illustrated following:
-Rotor tip clearance; not adjustable set by manufacturer
-Front and back face clearance; adjustable by shim
Rotor thickness and body depth are fixed at manufacturer. Therefore, with the correct rotor size
selected, the only maintenance adjustment that can be made is the proportion of front and rear
clearance. Measure the front clearance as follows:
1. The rotor to rotor housing back face clearance is maintained by the shim(s) (45).
2. Check that the rotor case is tight to the gearbox (1A). And check the rotor bolts (35) are tight.
3. Measure the clearance between the back face of the rotor case and the back of the rotor with
a feeler gauge with reference of the above recommended back face clearance.
4. If incorrect, adjust by adding or removing shim(s) (45) from behind the rotor case.
5. Check each rotor and adjust as necessary.
Fig. 33

18
Rotor Timing
Rotor timing is critical for the pump operation and must be precisely maintained to provide maximum
pumping efficiency, yet prevent contact between rotors during operation. If pumping efficiency is
below expectations, or if rotors contact during operation (within rated differential pressure), check
rotor timing and adjust if incorrect. Also check rotor timing after any gearbox dismantling when the
gears are removed and/or replaced.
Check Rotor timing as follows:
1. Assemble each rotor in its normal location on the drive shaft and the idle shaft. Assemble each
rotor bolt and tighten hand tight.
2. Rotate the shafts 30 degrees and measure gap as
illustrated by arrows in Figure 34. Rotate the
shafts 60 degrees to the opposite direction and
measure the gap as illustrated.
3. The Rotors are correctly timed when the gap
measured at both locations are equal. If the gap
is unequal, adjust the timing as follows.
4. Rotor timing is determined by the relative location
of the two helical gears (14) on the shafts. Gear
spacers (16) are used to adjust the location and
the timing. When adjusting timing, move only
one of the two gears.
5. Bend away the tab of the lock washer (12) on
drive shaft, loosen the lock nut and remove gear.
Insert a NEW gear spacer(6mm) on drive shaft,
gear, lock nut and lock washer consequently and
tighten referring the ‘Gearbox Assembly’ in page
22. Finally, adjust the rotor timing to be correct.
6. If the rotor timing is correct, measure the gap of the gear
between drive shaft and idle shaft using depth
micrometer shown in Figure 35. Adjust the gap using
spacer and shim(s) according to the below cases.
* If the gap is (+) value (idle shaft is more embossed
than drive shaft) as shown in Figure 36, combined
6mm spacer & shim(s) and add on the idle shaft to
make the gap equal.
* If the gap is (-) value (drive shaft is more embossed
than idle shaft) as shown in Figure 37, combined
5mm spacer & shim(s) and add on the idle shaft to
make the gap equal.
Fig. 34
Fig. 35
Fig. 36

19
Above cases of combinations (5mm & 6mm spacer,
0.1mm shim(s)) can be applied for ZP015 & 030 series
only. While the other bigger size of shim(s) & spacer
combination, but same concept, can be applied for
ZP060 & 130 series.
7. Reassemble the idle shaft by the same procedure as drive shaft after adjustment.
Fig. 37